2014 Wire Wizard Brochure
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Transcript of 2014 Wire Wizard Brochure
WW
cat
alog
201
4
Wire Wizard theartofwirefeeding
Wire Guide Modules, look at page 18
Check our new website at: www.wire-wizard.eu
Productcatalog weld wire dispensing systems
2
Introduction
New Wire Guide Modules The most spectacular innovation in years are the new Wire Guide Modules. A totally new concept of feeding wire. Philosophy:
- What causes the most friction in wire transport?
- Exactly, “the bends and curves in your conduit”
- Eliminate these curves, you’ll eliminate the friction.
Within this new way of thinking the straight ends of your wire feed are made with the familiar conduits and the bends are made with these Wire Guide Modu-les. Each module has a curve of 45 degrees and can be built together with other mo-dules in order to make a 90, 135 or 180 degrees curves. In this way large distan-ces can be bridged without assist.
Dear Welding Associate,
You’re about to enter the world of the Wire Wizard. This Wizard will hand you a solution for each wire feed problem you are faced with or will be in future.
Wire Wizard is the world leading brand in wire dispensing products. Started in 1985 by Elco Enterprices, Inc. in USA and brought over to Europe in 1999. Through anticipation of customer needs and ongoing dialogue with end users Wire Wizard created a distinct product line of High quality products.
What is Wire Wizard?
Wire Wizard is a range of products to dispense welding wire from any kind of spool or drum to any kind of wire feeder. This means that whatever kind of drums you’re using; Wire Wizard has a cone especially for your type of drum. And also that whatever brand of robot or manual welding machine you use; Wire Wizard has a connector specially for your type of wire feeder. In combination with the high quality conduit you are able to connect everything to anything.
the possibilitiesThe Wire Wizard program offers a total solu-tion for all your wire feeding problems with high quality products. With a simple combina-tion of products it is possible to equip every robot or welding machine with a drum placed at a variable distance. Extra advance is that every connection is made with quick disconnections. This makes it very easy to replace or clean the conduit. To change from one type of wire to another can be done very fast.
6 steps to your solutionWire Wizard keeps things simple. Each situa-tion is connected with a universal type of con-nector and also the conduit is easy to choose. This makes it very easy to compose your own set of equipment specially for your situation. In 6 steps this catalogue takes you to a perfect set of equipment.
Step 1 - Cone’s
Features:• Four standard designs fits all current drums• Constructed of tough polyethylene and guaranteed against breakage• Dual windows provide easy access for operator• Lifetime guarantee against breakage
Round dRum cone Round drum cone for standard fiber drums.Mounted with the metal ring supplied with the drum;
Size in cm Part Number51 cm WW10200C 52 cm WW10204C-STANDARD IN EUROPE 59 cm WW10234C 66 cm WW10260C
octagon dRum cone Octagon drum cone for octagonal packs. The lip securely anchors the cone to the pack.
Size in cm Part Number52 cm WWOC205 59 cm WWOC235 H
SquaRe dRum cone Square drum cone for square packs. The lip securely anchors the cone to the pack.
Size in cm Part Number54 cm WWSC-21 61 cm WWSC-24 72 cm WWSC-28
Round dRum coneRound drum cone for Economical or Environmental fiber drums. The lip securely anchors the cone to the drum
Size in cm Part Number51 cm WW10201F 58 cm WW10231F 66 cm WW10260F
3
Unbreakable polyethylene cone’s for all available drums
Size in cm Part Number 59 cm WWOC235 L LOW PROFILE HOOD
Wire
Gui
deM
odul
es
Chec
k pa
ge 1
8-19
This table helps you to choose the right cone for the drum you are using. Drum sizes have been supplied by the manufacturer who, reserve the right to change product standards without notice.
Cross reference table wire manufacturers
Step 1 - Choose the right cone
Wire manufacturer Packaging trade name WW article no.
Air Liquide 250 Kg Blue Shield WW10204CAir Liquide 400 Kg Blue Shield WW10234CAir Liquide 250 Kg Square pack WWSC-21Air Liquide 400 Kg Square pack WWSC-24Böhler-Welding 250 Kg ECO-Drum WW10204CBöhler-Welding 250 Kg ÖKO-Multi WW10204CBöhler-Welding 400 Kg Paper-Drum WW10260CElbor 250 Kg Drum 250-270 Kg WW10204CElbor 450 Kg Drum 450 Kg (Square) WWSC-28Elga 250 Kg Octagon Pac WWOC205Esab 100 Kg Marathon Pac Mini WWOC205Esab 250 Kg Marathon Pac WWOC205Esab 475 Kg Marathon Pac Jumbo WWOC235Gedik 50 Kg Economic 50 WW10200CGedik 250 Kg Big Pack 250 WW10204CGedik 500 Kg Big Pack 500 WW10234CGrytols Bruk 250 Kg Drum WW10204CGrytols Bruk 450 Kg Drum WW10234CKobelco 200 Kg Arrow Pac WW10204CKobelco 250 Kg Arrow Pac WW10204CLincoln 100 Kg Accu Trak Cube WWSC-24Lincoln 250 Kg Accu Trak Cube WWSC-24Lincoln 400 Kg Accu Trak Cube WWSC-24Lincoln 250 Kg Accu Trak Round WW10204CLincoln 400 Kg Accu Trak Round WW10204CMig-Weld 80 Kg Eco-Drum WW10201FMig-Weld 140 kg Square Pack WWSC-24Novametal 100 Kg Nova Mini Drum WW10204CNovametal 200 Kg Nova Drum WW10204CSafilo 250 Kg Safilo Drum WW10234CSelectarc 100 Kg Selectarc WW10204CSelectarc 200 Kg Selectarc WW10204CSelectarc 250 Kg Selectarc WW10204CSelectarc 300 Kg Selectarc WW10234CSidergas 150/300 Kg PAC 150/300 WWSC-21Sidergas 450 Kg PAC 450 WWSC-28Sidergas 550 Kg PAC 550 (24-7) WWSC-28Ugitech 250 Kg Drum WW10204CHyundai 250 Kg Ball pac WW10204CUgitech 250 Kg Octagon Drum WWOC205Valk Welding 250 Kg Octagon Drum WWOC20Valk Welding 250 Kg Eco Drum WW10201FValk Welding 500 Kg Eco Drum WW10260FWDI 80/250 Kg XS/S Round Drum WW10204CWDI >325 Kg M/L Round Drum WW10234CWDI >325 Kg EcoRack M WWOC205WDI 450 Kg EcoRack L WWOC235L
4
WLI WIRe LeVeL IndIcatoR
With the WLI Wire level indicator you can quickly see how much welding wire the drum still contains!
• design for 250 kg and 500 kg drums• for all brands of welding wire in
drums• works without a power supply,
air or any other medium
The direct pull kit is the most universal cone connector of the Wire Wizard program.
For 99% of all cases this is the perfect solution to connect the conduit to the cone
The direct pull contains a female connector, a washer and a ceramic inlet guide made in a derlin holder.
Step 2 - Cone connectors
WWa5-e34-nc (normally close) WWa5-e34-no (normally open)WIRe PReSence SenSoR SWItcH-24Vwith M-12 thread. Other switches are avai-lable upon request. Please call with specifi-cations for quote.
WWSB-m12WIRe PReSence SenSoR BLocKcan be added to WWDP or WWOA kits. M-12 thread is standard. Also available in M-18
HOOD
5
dIRect PuLL KIt
WIRe detectIon
The re-usable drumcore is special designed for coreless drums. To protect the wire from flipping over in the coreless center this drum core can be put inside the drum.
oRBItaL aRm KIt
The orbital arm is developed to solve problems which can occure during the dewinding of drums. Small diameter wires and heavy tangling wire can cause nuts inside the drum. With the orbital arm these problems can be solved easily.
Re-uSaBLe dRum coRe
WW-dP
WW-qdI
WW-oa-20H
WW-Ic-11
711mm
254mm
Insulator for the drum connection
WW-dI
Universal insulato-tion sleeve for all quick disconnects
WW-dP-I Direct pull kit with insulation sleeve
cone connectoR InSuLatoR
Step 3 - Conduits for Mild Steel
extRa FLexIBLe conduIt
Liner with a hard steel inner core which is made out of oval wire for a minimal resistance for the wire to pull through. This makes that the wire easily runs trough angles. With this hard inner
core and double insulation jacket these liners are stiff enough to bridge a small distance without a support, for example to a robot arm.
6
Conduits bought at bulk length can be easily cut at the right length and can be connected with a compression connector
extRa FLexIBLe conduIt In FIxed LengHtS WItH SWaged connectoRS
All conduits in our range are also available in fixed lengths with swaged connectors. For the FC-X we have made some standards.
Length* Article Number
1,5 m FCX015
3,0 m FCX030
5,0 m FCX050
8,0 m FCX080
10,0 m FCX100
12,0 m FCX120
2 Swaged connectors
1 x side with polymer strain relief
Part Dimensions in mm Connector Use for Order Bulk
Number inside x outside wire quantity length
FC-X-SW 2,3 x 9,00 mm A-10C-S 0,6 mm Per mtr 30,5 mtr
FC-X 6,0 x 12,70 mm A-10C-X 06 -1,6 mm Per mtr 30,5 mtr
FC-XH 7,5 x 15,50 mm A-10R 1,6 - 2,4 mm Per mtr 30,5 mtr
FC-XH-LW 10,0 x 19,00 mm A9/A6 2,4 - 4,0 mm Per mtr 30,5 mtr
toRcH LIneRS
The oval liner technology is also available for torch liners.
Part Dimensions in mm Use for Order Bulk
Number inside x outside wire quantity length
STL-1936 1,9 x 3,6 mm 0,6 - 1,2 mm 3/4/5 mtr set 50 mtr
STL-2946 2,9 x 4,6 mm 1,2 - 1,6 mm 3/4/5 mtr set 50 mtr
Wire Wizard:NO GAPS: SMOOTH ROUND EDGES
others:OPEN GAPS: SHARP EDGES
Part Dimensions in mm Use for Connector Order Bulk
Number inside x outside wire quantity length
EC-3 4,5 x 8,60 mm 0,6 mm A-10C-S Per mtr 152 mtr
EC-4 7,6 x 11,70 mm 0,6 - 1,6 mm A-10C-H Per mtr 152 mtr
EC-5 10,0 x 15,20 mm 1,6 - 2,4 mm A-10R Per mtr 152 mtr
EC-6 14,0 x 19,00 mm 2,4 - 4,0 mm A9 + A6 Per mtr 152 mtr
7
BLue PoLymeR conduIt In FIxed LengHtS WItH tHRead conncectoRS
All conduits in our range are also available in fixed lenghts with Thread connectors. For the EC-4 we have made some standards.
Length* Article Number
1,5 m EC4-015
3,0 m EC4-030
5,0 m EC4-050
Length* Article Number
8,0 m EC4-080
10,0 m EC4-100
12,0 m EC4-120
*Other lengths can be made at request
Thread connector
toRcH LIneRS and acceSSoRIeS
PoLymeR LIneR InSeRt a-4L-H
Wire Wizard provides a range of heat-resistant torch liners which exceeds the quality of the common liners in the market.
Part Material Dimensions in mm Use for Order Bulk
Number inside x outside ø wire quantity length
EC-1 Polymer 2,3 x 4,57 mm 1,0 - 1,6 mm per mtr 100 mtr
PHTL-1647 Polymer-carbon 1,6 x 4,7 mm 0,6 - 1,0 mm per mtr 100 mtr
PHTL-2347 Polymer-carbon 2,3 x 4,7 mm 1,2 - 1,6 mm per mtr 100 mtr
PHTL-3247 Polymer-carbon 3,2 x 4,7 mm 1,6 - 2,4 mm per mrt 100 mtr
TTL-2039 Teflon-carbon 2,0 x 3,9 mm 0,6 – 1,2 mm per mtr 80 mtr
TTL-2747 Teflon-carbon 2,7 x 4,7 mm 1,2 – 2,0 mm per mtr 80 mtr
Conduits Stainless Steel & Aluminum
BLue PoLymeR conduIt
Known throughout the industry for its longevity and low drag coefficient this dura-ble conduit has proven to outlast aluminum and stainless steel while still providing a minimum pull on the feed motor. The EC-4 is the most common of the blue polymer conduits.
Polymer conduit
Part Number
Description Use for liner with Outside diameter
TL-EN40 Thread/clamp end-nipple to connect liner in torch connector
3,9 - 4,0 mm
TL-EN42/LE42 “ 4,2 mm
TL-EN47 “ 4,7 mm
TL-LE40 Brass thread liner-end for use at liner-end in torchbody
3,9 - 4,0 mm
TL-LE42 “ 4,2 mm
a-4L-H 2,3 x 4,5 x 100 mm
The A-4L-H is designed to prevent the wire from shaving against the steel connectors
Step 4 - Conduit connectors
connectoRS FoR extRa FLexIBLe conduIt
Conduit FC-X-SW
Conduit FC-XH
Conduit FC-XH-LW
Conduit FC-X
Compression-female Quick dis. A-10R-QD
connectoRS FoR BLue PoLymeR conduIt
Conduit EC-3
Conduit EC-4
Conduit EC-5
Conduit EC-6
For c
onne
ctor
s w
ith a
str
ain
relie
f add
-SR
to th
e ar
ticel
num
ber
For c
onne
ctor
s w
ith a
long
str
ain
relie
f add
-SR
L to
the
artic
el n
umbe
r
RePLacement FeRRuLeS FoR comPReSSIon connectoRSChoice of sizes for the right compression fit for the application.
Ferrules CONNeCTOrs
A-9-FE A-9
A-10RFE A-10R A-10RP
A-10XFE A-10C-X A-10XP
A-10CFE A-10C-H A-10HP
A-10SFE A-10C-S A-9-Fe A-10rFe A-10XFe A-10CFe A-10sFe
8
Compression- bayonet A-10C-S
Compression- bayonet A-10-CX
Compression- 1/4 thread A-10-XP
Compression- bayonet A-10C-R
Compression- 1/4 thread A-10-RP
Compression- bayonet A-9+A-6
Compression- bayonet HD A-9+A-6HD
Compression- 1/4 thread A-10-HP
Compression- 1/2 thread A-10HM
Compression- Union A-10RU
Compression- Union A-9U
Compression- 1/4 thread A-10-RP
Compression bayonet A-10-CS
Compression bayonet A-10-CH
Compression bayonet A-10-R
Compression bayonet A-9+A-6
Self-treading- bayonet A-16F-3
Self-treading- bayonet A-16F-4
Self-treading- bayonet A-16F-5
Self-treading- bayonet A-16F-6
Compression- Union A-10RU
Compression- Union A-9U
Compression- 1/4 thread HD A-9+A-6HD
Compression-inline 1/2 thread A-10-XM
the a-14 bulkhead connector
a-4 female connector 1/4” - nPt-m
The A-14 bulkhead connector has a 1/4” NPT female thread at both sides, and can therefore be used at both sides as well.
a-14B Bracket
95 mm
The A-14 bulkhead connector in combination with the A-4 female connector is used to make an insulated connection in a steel plate for example a wire feeder box. The A-14B is a universal bracket which can be used to mount the bulkhead connector.
Step 5 - Feeder connectors 1
PLate oR BuLKHead connectIon
9
a-14 BK Bulkhead connector kit
quIcK dISconnectS (FemaLe) Bayonet tHRead connectoR
tHRead adaPteRS BSP (gaS)
maLe Bayonet eSaB dRum con.
Hd HeaVy duty connectoRS FoR SuBmeRged aRc WeLdIng
use only for Hd (large) bayonet connectors
a-4 a-4St a-4S a-5 Brass -copper Steel Ring + Nut Brass-copper 1/4” NPT 1/4” NPT 1/4”BSP-M (GAS) 1/2” NPT-M
a-4S for non isolated plate connection
WWtt-dP for plate connection + ceramic insert
a-4Hd a-3Hd a-3Hd12 a-3Hd34 a-6Hd3/8”NPT-M 3/8”NPT-F 1/2”BSP-F 3/4”BSP-F 1/2”NPT-F
A-15 A-16F3 A-16F5 1/4” BSP (GAS) 1/8” NPT-F 3/8” NPT-F A-15-1 7/16”– 20 A-16F4 A-16F6 A-15-2 1/4” NPT-F 1/2” NPT-F 9/16”– 20
9/16”-18 UNF
1/4 BSP (GAS)
quIcK dISconnect WItH InSIde tHRead to mount dIRectLy at tHe InLet guIde oF tHe FeedeR
A-3 A-3 A-3QDF-1 A-3QDF-2 A-3QDF-3 A-3QDF-4 A-3QDF-5 A-3QDF-6 OTC Motoman Panasonic
a-15e 3/8”BSP-M
a-17g 1/4”F 3/8” M
a-18g 1/4”F 1/2” M
a-18g1 3/8”F 1/2” M
InLet guIdeS WItH quIcK dISconnect SPecIaL FoR one BRand
Step 5 - Feeder connectors 2
13,00 60,00
2,20
13,00
55,00
5,00
12,00
47,00
3,20
9,50
33,00
a-1otc-Fx a-1FRo a-2FRo a-1FRo-B a-1mot-HP a-1na-5 a-1B-c OTC Fronius Feeder Fronius Feeder Fronius Feeder Motoman Lincoln Miller Wire Hyper Feeder Feeder Straightener & PFA Models
70,00
2,00
13,00
3,20
14,00
2,20
40,00
3,209,50
70,00
3,20
8,50
70,00
5,00
9,50
44,50
3,20
8,00
70,00
3,20
9,50
a-1a* a-1aH330 a-1a-c a-1a-d a-1aH a-1a-4.5 9,5 mm Probe 8,5 mm Probe 9,5 mm Probe 9,5 mm Probe 8,0 mm Probe 9,5 mm Probe Miller Wire Feeder Miller Wire Miller Series 74 Feeder (Sm. Wire) Wire Feeder
3,00
9,50
5,00
8,00 M8
23,00
44,50
114,00
A-1MOT-Au A-1lN-23A A-1lN-23B Motoman Lincoln Wire Lincoln Cloos Cebora ESAB ESS
2,20
12,00
37,00
6,40
12,00
35,00
3,2011,20
103,00
6,90
4,00
a-3 a-3qdF-4
a-2Pa a-8m PaWFS-12
15,00
41,0063,50
2,00
9,50
19,00
17,40
10
11
Step 5 - Feeder connectors 3
InLet adaPteRS WItH FemaLe tHRead
5,00
12,70
44,50
9,50
31,50
51,00
19,70
40,00
1/4" NPT-F
1/4" NPT-F
1/4" NPT-F
1/4" NPT-F
6,90
6,905,005,00
22,00
32,00
1/4" NPT-F
1/4" NPT-F
4,00
17,40
63,50
1/4" NPT-F
a-2e a-1e a-1H a-1Ln a-1m a-1Pa a-1otc a-8F ESAB 4-48 ESAB All Hobart Lincoln Miller Panasonic OTC Miller
6,90
53,50
1/4" NPT-F
5,00
12,00
38,00
22,00
44,50
21,00
A-4A-5
deRLIn InLet guIde ceRamIc InSeRt
3,2012,70
44,50
A-1HC
9,50
3,20
A-1CM
29,00
9,503,20
44,50
A-1MC
12,70
3,20
A-1Cs
These Derlin inlet guides can be used for applications for Aluminium or stainless steel wires.
deRLIn InLet guIde WItH tHRead
9,50
3,00
44,50
1/2"-14
NPT-F
A-1Ds-1
1/2"-14
NPT-F
A-1Ds-2
12,70
3,20
20,00
12,70
3,00
44,50
1/2"-14
NPT-F
A-1Ds-3
3/8"-18
NPT-F
A-1Ds-4
12,70
3,20
29,00
20,00
use a-4 (1/4” nPt-m)
A-17G 1/4”F 3/8”M
A-18G 1/4”F 1/2”M
A-18G1 3/8”F 1/2”M
1/4"
NPT-M3/8"-18
NPT-M
1/2"-14
NPT-M
for HD Bayonet
A-4HD
A-1Ds-4 pFA
19,00
5,00
30,00
3/8"-18
NPT-F
in/o
ut P
Fa-u
nit
A-1Cs pFA
5,019,20
30,00
in/o
ut P
Fa-u
nit
Inline connectorsThe conduit runs through the whole connector into the plastic inlet guide.In this way the wire is prevented from shaving against the metal connector. Thread=1/2” NPT-M
The A-10-XM is used for the FC-X conduit. The A-10-HM is used for the EC-4 conduit.
FeedeR InLet cRoSS-ReFeRence cHaRt
12
Step 5 - Feeder connectors 4
22,00
a-1a-4.5 (see page 10) 9,50
3,20
a-1SKS
FeeDer wire wizArDTM
MANuFACTurer FeeDer Type iNleT GuiDe p/N
ESAB ALL (except 4-48) A-1LN-23B 4-48 A-2E and A-4
Fanuc Servo Torch A-3QDF-6 and A-23
Fronius Feeder without Set Screw A-1FRO-B Feeder with Set Screw A-1FRO Feeder with Stripped Set Screw A-2FRO
Hobart Series 27 A-1H and A-4 A-1A, A-1A-4.5 Models with 3/4"-16 Thread A-1A and A-22 A-1AH330 and A-1MOT
Kobelco Male Threaded Inlet 1/2"-20 A-3QDF-4
Lincoln Electric PF Series A-1LN and A-4 LN-7, LN-9, and LN-25 A-1A LN-8 A-1H and A-4 NA-3 and NA-5 A-1NA-5 Synergic 7 A-1B-C LF-72 A-1LN and A-4 Series 10 A-1LN and A-4 Servo Torch A-2LN-AK
Miller Most Models A-1A-C, A-1M and A-4, or A-1A 22A A-1AK Auto Axcess A-1A-C Series 74 A-1A-4.5 Series 75 PAWFS-12 and A-3 RAD 400 A-1LN-S and A-3
Motoman Female Inlets A-1AH330 and A-1MOT Male Threaded Inlets A-3QDF-3 Hyper Feeder A-1MOT-HP
OTC/ Male Threaded Inlet 7/16"-20 A-3QDF-2 DAIHEN Male Threaded Inlet 9/16"-18 A-3QDF-4
Panasonic Female Inlet A-1PA and A-4 Female Inlet A-2PA and A-3QDF-4 Male Threaded Inlet A-3QD F-4
SKS All Types A-1SKS and A-1A-4.5 Cloos 12 mm A-1LN-23B EWM 12 mm A-1LN-23B Cebora 12 mm A-1LN-23B
a-1a (see page 10) 9,50
3,20
3/4" – 16a-22
SKS FeedeR adaPteR
3,20
8,50a-1aH330 (see page 10)
3/4" – 16
a-1mot
connectoR LIneR FoR aLu
a-4L-H 2,3 x 4,5 mm
Designed to avoid any metalic contactinside the connectors. Used for Aluminum and other non-ferrous metals.
The A-1AK universal inlet kit is an inlet adapter with four phenolic bushings to make a solid and stable fitting in several sizes of holes.
unIVeRSaL InLet guIde WItH quIcK dISconnect
Id x od 15,90 x 22,20 mm
Id x od 15,90 x 22,20 mm
Id x od 15,90 x 19,00 mm
Id x od 15,90 x 19,00 mm
Id x od 9,5x 12,70 mm
Id x od 9,5 x 15,90 mm
Id x od 9,5 x 15,70mm
Id x od 9,5 x 12,70 mm
Id x od 9,5 x 12,00 mm
a-1aK
a-1aKe
a-7e = BuSHIngS onLy
a-7 = BuSHIngS onLy
SPecIaL eSaB
HoBaRt adaPteRKIt
motoman adaPteRKIt
13
Wire straighteners
sMAll wire sTrAiGHTeNer FiTTiNGs
Wire WizardTM manufactures four versions of wire straighteners that can be used to straighten or recast all types of wire. The main body is constructed of aluminum, making our straighteners some of the lightest in the market. All models are equipped with a locating calibration on the face of the unit and a fine adjust-ment scale on the tension knob. This results in an extremely fast and accurate setting of wire cast. Our full range of fittings and inlet guides guarantee a trouble-free fit for any application or system.
sMAll wire sTrAiGHTeNers MODels ws-1000 & ws-1000AFor wire sizes 0,8 - 1,6mm (Order WS-1000A for Aluminum Wire)Dimensions: 95mm W x 78mm H x 41.3mm D
Weight: 450 gr
MeDiuM wire sTrAiGHTeNer MODel ws-1000HFor wire sizes 1.6 - 2.4mm Dimensions: 145mm W x 84.7mm H x 47.63mm D
Weight: 800 gram
STEEL WIRE STRAIGHTENER
A-1M-sMILLER
A-1lNs
SAME ID & OD AS A-1lNs
LINCOLN INLET (A-1LN)OR A-3 DISCONNECT
lArGe wire sTrAiGHTeNer MODel ws-1000lFor wire sizes 3,2 - 6,0 mm Dimensions: 220mm W x 103.8mm H x 57.2mm D
Weight: 1800 gram
iNsulATeD MOuNTiNG KiTs Available for all models
wss-100-iKSmall
wsM-100-iKMedium
wsl-100-iKLarge
FiTTiNGs FOr ws-1000H
A-16M-sTAttaches to QD
A-16M-sT-HDAttaches to QD
A-4 Quick Disconnect
FiTTiNGs FOr ws-1000l
A-1lN Inlet Guide
A-4HD Quick Disconnect
A-1lN-lw Inlet Guide
ws-1000 Drive rollsU-Groove Drive Rolls for Steel Wire
ws-1000-A Drive rollsV-Groove Drive Rolls for Aluminum Wire
Order A-1lN-K for Inlet/Outlet Kit (includes two A-1LN’s)
Order A-1lN-K-lw for Inlet/Outlet Kit (inc. two A-1LN-LW’s)
a-1qd
25,40 12,70
12,70
12,70
12,70
17,50
17,50
32,00
4,00
3,20
2,80
3,20
1/4 NPT Thread
1/2 NPT Thread
End view of ceramic
insert
End view of ceramic
insert
a-1LnS
a-1c-S DERLIN
a-1c-S DERLIN
WS-1000
WS-1000a
12,70
12,70
4,00
4,00
2,30
2,80
2,80
9,50
2,80
25,40
25,40
65,00
32,0012,70
9,00
44,00
1/4 NPT Thread
1/4 NPT Thread
1/2 NPT Thread
direct pull page 5
Pneumatic Feed assist for long conduit runs
page 16-17
Wire guide modules
page 18-19
direct pull with wire detection
page 5
All these options can be used in combination with a cone of your choise
WIRe FeedeR
A-10C-X A-10R A-9/A-6
FC-XSTANDARD, EXTRA FLEXIBLE
FC-XH-LWLARGE-WIRE, EXTRA FLEXIBLE
FC-XHHEAVY-DUTY, EXTRA FLEXIBLE
EC-3, 4, 5 or 6CONDUIT BLUE POLYMER
14
page 6 & 7
page 8
FC-XSTANDARD, EXTRA FLEXIBLE
FC-XH-LWLARGE-WIRE, EXTRA FLEXIBLE
FC-XHHEAVY-DUTY, EXTRA FLEXIBLE
EC-3, 4, 5 or 6CONDUIT BLUE POLYMER
FC-XSTANDARD, EXTRA FLEXIBLE
FC-XH-LWLARGE-WIRE, EXTRA FLEXIBLE
FC-XHHEAVY-DUTY, EXTRA FLEXIBLE
EC-3, 4, 5 or 6CONDUIT BLUE POLYMER
Combination of femaleconnector and bulkhead.Perfect for plate mounting. page 9
Universal inlet kitSet of 1 inlet adapterand 4 adapter bushings page 12.
Inlet adapter for specificbrand. Choose one at
page 10.
A-14 A-4
a-1aK
a-1FRo
a-14 A-4
a-14B (Bracket) page 9
A-9/A-6 A-10R A-10C-X
15
FC-XSTANDARD, EXTRA FLEXIBLE
FC-XH-LWLARGE-WIRE, EXTRA FLEXIBLE
FC-XHHEAVY-DUTY, EXTRA FLEXIBLE
EC-3, 4, 5 or 6CONDUIT BLUE POLYMER
page 6 & 7
page 8
page 8
With step 1 to 5 you already made a complete set of Wire Wizard products to equip one installation. The last thing you might need to think about is the distance you want to cross with the conduit. Wire Wizard offers you the possibility to bridge bigger distances than you have done up till now.
A great advance of the Wire Wizard system is the distance, which can be bridged by this system. Everybody knows that normally the distance from the wire feeder to the spool or drum can be maximum 5 to 10 meters. This makes that for large installations it’s difficult to get the drum close enough to the feeder, and sometimes it’s even impossible to work with drums. This forces us to use small spools, which means that production will stop with every use of 15 kg of welding wire. A great loss of production time.
Wouldn’t it be great if the distance between drum and feeder were just no problem at all? Wire Wizard hands you the solution to all these problems. By using the Pneumatic Feed Assist (PFA) you can bridge distances up to 30 meters.
This opens lots of opportunities to place the drum at a large distance to avoid great loss of time by replacing and handing the drums. Its even possible to leave the drum at the pallet and don’t move it at all.
The PFA-Unit must not be compared with the traditional Push-Pull systems. Trough the years Push-pull systems got a bad reputa-tion in the market because they damage the wire, are very sensitive for technical trouble and very fragile. The great advance of the PFA-Unit is that it works with one unit only, and works completely independent from the wire feeder of the machine. This makes that you can add it to any running system you like.
The friction free transport of wire, which these systems create has the advance that wearing of the liners will be reduced to mi-nimum and rasping of the wire feed rollers will be history.
By using a feed assist you can even put the wire conduit in the drag chain or cable car-rier together with the other cables leading to the robot arm.
Step 6 -Wire feed assist 1
unLImIted dIStance WItH PneumatIc WIRe Feed aSSISt
tHe PFa-unIt
FeatuReS
• Works independent and requires only shop air to operate
• Enables long conduit runs (up till 30 metres)
• Reduces wire drag in the conduit and extends conduit life
• Prevents drive roll “slippage” and prevents burn back
• Increases arc-on time
• Ideal for soft metals like Aluminium and Silicon bronze
• Works with any kind of wire packaging
• Works also in combination with another PFA in the same conduit.
16
aPPLIcatIon
Step 6 -Wire feed assist 1
17
Step 6 -Wire feed assist 2
The Solenoid double kit is used in cases where the PFA needs to be able to run in two direc-tions.With this kit the PFA is not only able to feed the wire but also to pull back the wire. This option is used for robots with a Arc-restart function.Arc-restart means that the wire is pulled back in order to make a restart.If the feeder pulls the wire backwards the PFA need to run backwards too in order to avoid wire deformation.
Includes valve, hose, connectors and cable.
PFa-unIt StandaRd Set Product Part number
PFA unit for 1,0 mm wire (installation set included) PFA10
PFA unit for 1,2 mm wire (installation set included) PFA12
PFA unit for 1,4 mm wire (installation set included) PFA14
PFA unit for 1,6 mm wire (installation set included) PFA16
Other diameters at request
Outlet guide for PFA with Quick disconnect A-1-BC
Drum mounting installation set (excl. Outlet guide) PFA-DA
Filter/Regulator/Lubricator PFA-FRL
118 ml bottle PFA lubricant PFA-OIL
U-groove Feed roll 1,0mm for PFA (per piece) WW072000
U-groove Feed roll 1,2mm for PFA (per piece) WW053701
U-groove Feed roll 1,4mm for PFA (per piece) WW053702
U-groove Feed roll 1,6mm for PFA (per piece) WW053706
Other diameters at request
V-Knurled Feed roll 1,0mm for PFA (per piece) WW132958
V-Knurled Feed roll 1,2mm for PFA (per piece) WW132957
V-Knurled Feed roll 1,4mm for PFA (per piece) WW132956
V-Knurled Feed roll 1,6mm for PFA (per piece) WW132955
Other diameters at request
A-1B-C Outlet adapter
PFA motor
PFA -FRL filer/regu-lator / lubricator
including hose
PFA-DA Drum adapter kit
Air tool lubricant included
PFA unit is supplied as a complete set to install the PFA-unit, including all the items in this drawing, except for the drumhood.
drumhood
PFa-unIt oPtIonS and acceSSoIReS
PFa-SR SILenceR/RecLaSSIFIeR 24-VoLt SoLenoId SIngLe-KIt
Separates oil from the used com-pressed air. Herewith it prevents pneumatic oil spatter.
The PFA-SR also reduces the noice of the air exhaust.
To install the PFA-SR the standard air exhaust needs to be removed.
PFa-Wm Remote mounting BracketMounts Feed Assist to walls or other surfaces
24-Volt Solenoid kit used to reduce the consumption of compressed air by the PFA.The solenoid is placed before the FRL and switches the air pressure on and off.
The signal the solenoid uses can be con-nected parallel with the gas valve, or in case of SAW welding, parallel with the powder valve.
In both cases the PFA is always running when the wire feeder is running.
PFa-WaLL-BRacKet 24-VoLt SoLenoId douBLe-KIt
PFa-SK
PFa-SK2
PFa-SR
Wire Guide Modules
installation example
• The new way of thinking in feeding wire• What causes the friction in your wire supply?... the bends ! • Eliminate the bends, you’lle eliminate the friction• Feed over 30 meters without assist
• Create any angel you like by connecting the modules.• For all kinds of wire from 0,6 to 2,4 mm • Much cheaper than other roller products• 3 YEARS GuARAnTEE (excludes damage caused by contaminants)
lightweight durable polymer body
Heavy duty rollers with bearings
Conduit connection going to feeder
Wire from source
2x 45ºdegree wire guide modules combined
to a 90º angle
45º guide module
Wire guide module & end Cap assemblies
90º guide module
Assembled with End Caps
Assembled with End Caps
To drum or bigspool or in case of SAW to turntable
WWdp
FC-x
Con
duit
ass
embl
y
a-1
0xm
Con
duit
ass
embl
y fo
r eC
-3,
eC-5
FC
-xH
, FC
-xH
-lW
& F
C-x
-sW
eC-4
Con
duit
ass
embl
y
a-1
0Hm
a-10xm For use with FC-x Conduit
a-10Hm For use with eC-4 Conduit
a-5 For use with any male connector
18
To wire feeder, choose the right adapter at page 10
Tapered end of insert always faces wire path direction
wire direction
Wire Guide Modules
19
FLOOR MOUNTING BRACKETCELL WALL MOUNTING KIT,DOUBLE SIDED
END CAP CONNECTORS90° MINI GUIDE MODULE45° WIRE GUIDE MODULES
WIRE WIZARD® POLYMER CONDUITCONDUITS & FITTINGS
WGM-1For solid wire
up to 5/64" (2mm)
WGM-1-SFor cored &
stainless wireup to 5/64" (2mm)
WGM-LW-1For large wire5/64" to 3/32"(2mm-4mm)
L-BRACKET MOUNTING KIT
Part #WGM-LBM-BRKT
CELL WALL MOUNTINGKIT, SINGLE SIDED
Part # WGM-WK-1-1
WGM-ECK-50(use -25 for A-4 orA-4-ST disconnect)
WGM-ECK-LW-50 For WGM-LW-1(use -38 for A-4HD disconnect)
FACE MOUNT BRACKET KITAllows 360° directional adjustment
GUIDE MODULE STAND FOR MEZZANINE APPLICATIONFor applications where wire source is above weld cell
Part #WGM-A-10BK
Part # WGM-WK-2-1
Part # WGM-UAAdapter Kit Only
Part # WGM-UAKIncludes Bracket
360° UNION ADAPTER KITAllows dual 360° directional
adjustment
Each kit includesone A & one B
end cap
Add WGM-A5 or order WGM-2-BRKTfor insulated connections
Part # WGM-M-1Uses same end caps as WGM-1
End CapA
End Cap B
Allows tight90° turns for
solid wires up to.052 (1.3mm)
*See catalog orwebsite for additionaloptions & accessories
6" (152mm)
Part #WGM-WK-1-3Adjustable for
up to 3" (76 mm)thick walls
Part #WGM-3-BRKT
Side Mount Bracket
Part #WGM-PFA-STANDIncludes stand and oneadjustable extension arm
Adjustableheight from50" –86"(1.3-2.2m)
Adjustablearm lengthfrom 4" –19"(102-483mm)
Adjustableheight from50" –86"(1.3-2.2m)
Adjustablearm lengthfrom 4" –19"(102-483mm)
Wire Pilot® FeedAssist Option
Wire Wizard®Fire Resistant
Drum Covers &Dollies Available
Optionalswivel
with 90°module
Drum -or-Wood Reel Drum -or-
Wood Reel
WGM-A-10BK
Additionalarm, part #WGM-PFA-
STAND-ARM
Part #WGM-PFA-STAND
Con
duit
to w
ire fe
eder
ADJUSTABLE WALL MOUNT BRACKET
Part #WGM-FLM
Modules maybe attached to
one or bothsides
GUIDE MODULE STAND FORDRUM OR WOOD REEL APPLICATION
Wire Spool OptionWGM-PFA-STAND-4
EC-3-R (4.4mm I.D.)Fittings: A-16F-3 or A-10C-S EC-4-R (7.6mm I.D.)Fittings: A-16F-4 or A-10C-H
EC-5 (10.2mm I.D.)Fittings: A-16F-5 or A-10R
EC-6 (14mm I.D.)Fittings: A-16-F-6 or A-9
Threaded Connector
Guide Module End Cap
WGM-A5 Insulated ConnectorScrew-on Fitting(A-16F-#)
A-5 Quick DisconnectCompression(A-10##)
WIRE WIZARD® EXTRA FLEXIBLE CONDUITCONDUITS & FITTINGS
*See catalog orwebsite for additionaloptions & accessories
FC-X (6.1mm I.D.)Fitting: A-10C-X FC-XH (7.4mm I.D.)Fitting: A-10R
FC-XH-LW (10mm I.D.)Fitting: A-9
FC-X-SW* (2.3mm I.D.)Only for wire .035 & under
Threaded Connector
Guide Module End Cap
WGM-A5 Insulated ConnectorCompression(A-10##)
A-5 Quick DisconnectSwaged Fitting(Pre-cut only)
WWDPDirectPull Kit
WWDPDirectPull Kit
Part #WGM-1-BRKT
45° MODULE HANGINGBRACKET KIT
HOOD SWIVEL KIT
90° HANGING BRACKET KIT
Part #WGM-1-90-BRKT
(WGM-LW-BRKT for WGM-LW-1)
A-10HMFor EC-4-R
A-10XMFor FC-X
A-10RMFor FC-XH & EC-5
A-9For FC-XH-LW
WGM-A5Insulated Connector
with quick disconnect
A-5Quick Disconnect forWGM-1 & WGM-1-S
A-4HDQuick Disconnect for
WGM-1-LW
DRUM HOOD MOUNTING KIT
Part #WGM-DK
WELD-ON OR BOLT-ONMOUNTING BRACKET
SUPPORT BRACKET SLOTTED SUPPORT BRACKET 45° ANGLE SUPPORT BRACKET
FEEDER INLET MOUNT KITMounts to feeder through
bracket or panel
Part #WGM-024
Part #WGM-021
Part #WGM-025
Part # WGM-EA-10Extends 10" (254 mm) to 18" (457 mm)
Part # WGM-EA-20Extends 20" (508 mm) to 36" (914 mm)
Part #WGM-IKExcludesBracket
Sampleinstallationon bracket
Allows 360°rotation ontop of drum
cover.
Part #WGM-HSK
Part #WGM-4-BRKT
Part #WGM-044
Part #WGM-DP-LW
Includes ceramicinlet that will
not shave wire
Part #WGM-SMB-3
GUIDE MODULEDIRECT PULL INLET
STACKABLE GUIDE MODULE BRACKETAllows mounting of up to 3 stacked modules
Part #WGM-CM-1Extends 2" (51 mm) to13" (330 mm),adjustable heightup to 6.5" (165 mm)
Part #WGM-2-BRKT
ADJUSTABLE EXTENSION ARMFor installation at the top of the weld cell wall
INSULATED FACE MOUNT BRACKET KITAllows 360° directional adjustment
CONDUIT CONNECTORS
TURN TABLE MODULE ADAPTERSecures Modules to Wire Wizard® Turn Table
PIVOTING ADJUSTABLE EXTENSION ARMSBoth arms pivot upward to allow easy wire feeding from drums & reels
Part #WGM-MSK
Creates 360°rotation pointbetween two
Modules
GUIDE MODULE SWIVEL KITS ADD-ON SWIVEL KITS
Part #WGM-PFA-SWFor the WirePilot® FeedAssist
Part #WGM-NSW-SWFor theNon-Stop™DispensingSystem
DETACHABLE QD CONNECTORSTHREADED CONNECTORS
Use Part #WGM-PFA-AKfor fixed mount
Compatible withWGM-1, WGM-1-S &
WGM-LW-1
A-5 with U-005insulator sleeve
Part #WGM-FSKCreates 360°rotation pointat the feeder
Part #WGM-1-BRKT
45° MODULE HANGINGBRACKET KIT
HOOD SWIVEL KIT
90° HANGING BRACKET KIT
Part #WGM-1-90-BRKT
(WGM-LW-BRKT for WGM-LW-1)
A-10HMFor EC-4-R
A-10XMFor FC-X
A-10RMFor FC-XH & EC-5
A-9For FC-XH-LW
WGM-A5Insulated Connector
with quick disconnect
A-5Quick Disconnect forWGM-1 & WGM-1-S
A-4HDQuick Disconnect for
WGM-1-LW
DRUM HOOD MOUNTING KIT
Part #WGM-DK
WELD-ON OR BOLT-ONMOUNTING BRACKET
SUPPORT BRACKET SLOTTED SUPPORT BRACKET 45° ANGLE SUPPORT BRACKET
FEEDER INLET MOUNT KITMounts to feeder through
bracket or panel
Part #WGM-024
Part #WGM-021
Part #WGM-025
Part # WGM-EA-10Extends 10" (254 mm) to 18" (457 mm)
Part # WGM-EA-20Extends 20" (508 mm) to 36" (914 mm)
Part #WGM-IKExcludesBracket
Sampleinstallationon bracket
Allows 360°rotation ontop of drum
cover.
Part #WGM-HSK
Part #WGM-4-BRKT
Part #WGM-044
Part #WGM-DP-LW
Includes ceramicinlet that will
not shave wire
Part #WGM-SMB-3
GUIDE MODULEDIRECT PULL INLET
STACKABLE GUIDE MODULE BRACKETAllows mounting of up to 3 stacked modules
Part #WGM-CM-1Extends 2" (51 mm) to13" (330 mm),adjustable heightup to 6.5" (165 mm)
Part #WGM-2-BRKT
ADJUSTABLE EXTENSION ARMFor installation at the top of the weld cell wall
INSULATED FACE MOUNT BRACKET KITAllows 360° directional adjustment
CONDUIT CONNECTORS
TURN TABLE MODULE ADAPTERSecures Modules to Wire Wizard® Turn Table
PIVOTING ADJUSTABLE EXTENSION ARMSBoth arms pivot upward to allow easy wire feeding from drums & reels
Part #WGM-MSK
Creates 360°rotation pointbetween two
Modules
GUIDE MODULE SWIVEL KITS ADD-ON SWIVEL KITS
Part #WGM-PFA-SWFor the WirePilot® FeedAssist
Part #WGM-NSW-SWFor theNon-Stop™DispensingSystem
DETACHABLE QD CONNECTORSTHREADED CONNECTORS
Use Part #WGM-PFA-AKfor fixed mount
Compatible withWGM-1, WGM-1-S &
WGM-LW-1
A-5 with U-005insulator sleeve
Part #WGM-FSKCreates 360°rotation pointat the feeder
FLOOR MOUNTING BRACKETCELL WALL MOUNTING KIT,DOUBLE SIDED
END CAP CONNECTORS90° MINI GUIDE MODULE45° WIRE GUIDE MODULES
WIRE WIZARD® POLYMER CONDUITCONDUITS & FITTINGS
WGM-1For solid wire
up to 5/64" (2mm)
WGM-1-SFor cored &
stainless wireup to 5/64" (2mm)
WGM-LW-1For large wire5/64" to 3/32"(2mm-4mm)
L-BRACKET MOUNTING KIT
Part #WGM-LBM-BRKT
CELL WALL MOUNTINGKIT, SINGLE SIDED
Part # WGM-WK-1-1
WGM-ECK-50(use -25 for A-4 orA-4-ST disconnect)
WGM-ECK-LW-50 For WGM-LW-1(use -38 for A-4HD disconnect)
FACE MOUNT BRACKET KITAllows 360° directional adjustment
GUIDE MODULE STAND FOR MEZZANINE APPLICATIONFor applications where wire source is above weld cell
Part #WGM-A-10BK
Part # WGM-WK-2-1
Part # WGM-UAAdapter Kit Only
Part # WGM-UAKIncludes Bracket
360° UNION ADAPTER KITAllows dual 360° directional
adjustment
Each kit includesone A & one B
end cap
Add WGM-A5 or order WGM-2-BRKTfor insulated connections
Part # WGM-M-1Uses same end caps as WGM-1
End CapA
End Cap B
Allows tight90° turns for
solid wires up to.052 (1.3mm)
*See catalog orwebsite for additionaloptions & accessories
6" (152mm)
Part #WGM-WK-1-3Adjustable for
up to 3" (76 mm)thick walls
Part #WGM-3-BRKT
Side Mount Bracket
Part #WGM-PFA-STANDIncludes stand and oneadjustable extension arm
Adjustableheight from50" –86"(1.3-2.2m)
Adjustablearm lengthfrom 4" –19"(102-483mm)
Adjustableheight from50" –86"(1.3-2.2m)
Adjustablearm lengthfrom 4" –19"(102-483mm)
Wire Pilot® FeedAssist Option
Wire Wizard®Fire Resistant
Drum Covers &Dollies Available
Optionalswivel
with 90°module
Drum -or-Wood Reel Drum -or-
Wood Reel
WGM-A-10BK
Additionalarm, part #WGM-PFA-
STAND-ARM
Part #WGM-PFA-STAND
Con
duit
to w
ire fe
eder
ADJUSTABLE WALL MOUNT BRACKET
Part #WGM-FLM
Modules maybe attached to
one or bothsides
GUIDE MODULE STAND FORDRUM OR WOOD REEL APPLICATION
Wire Spool OptionWGM-PFA-STAND-4
EC-3-R (4.4mm I.D.)Fittings: A-16F-3 or A-10C-S EC-4-R (7.6mm I.D.)Fittings: A-16F-4 or A-10C-H
EC-5 (10.2mm I.D.)Fittings: A-16F-5 or A-10R
EC-6 (14mm I.D.)Fittings: A-16-F-6 or A-9
Threaded Connector
Guide Module End Cap
WGM-A5 Insulated ConnectorScrew-on Fitting(A-16F-#)
A-5 Quick DisconnectCompression(A-10##)
WIRE WIZARD® EXTRA FLEXIBLE CONDUITCONDUITS & FITTINGS
*See catalog orwebsite for additionaloptions & accessories
FC-X (6.1mm I.D.)Fitting: A-10C-X FC-XH (7.4mm I.D.)Fitting: A-10R
FC-XH-LW (10mm I.D.)Fitting: A-9
FC-X-SW* (2.3mm I.D.)Only for wire .035 & under
Threaded Connector
Guide Module End Cap
WGM-A5 Insulated ConnectorCompression(A-10##)
A-5 Quick DisconnectSwaged Fitting(Pre-cut only)
WWDPDirectPull Kit
WWDPDirectPull Kit
FLOOR MOUNTING BRACKETCELL WALL MOUNTING KIT,DOUBLE SIDED
END CAP CONNECTORS90° MINI GUIDE MODULE45° WIRE GUIDE MODULES
WIRE WIZARD® POLYMER CONDUITCONDUITS & FITTINGS
WGM-1For solid wire
up to 5/64" (2mm)
WGM-1-SFor cored &
stainless wireup to 5/64" (2mm)
WGM-LW-1For large wire5/64" to 3/32"(2mm-4mm)
L-BRACKET MOUNTING KIT
Part #WGM-LBM-BRKT
CELL WALL MOUNTINGKIT, SINGLE SIDED
Part # WGM-WK-1-1
WGM-ECK-50(use -25 for A-4 orA-4-ST disconnect)
WGM-ECK-LW-50 For WGM-LW-1(use -38 for A-4HD disconnect)
FACE MOUNT BRACKET KITAllows 360° directional adjustment
GUIDE MODULE STAND FOR MEZZANINE APPLICATIONFor applications where wire source is above weld cell
Part #WGM-A-10BK
Part # WGM-WK-2-1
Part # WGM-UAAdapter Kit Only
Part # WGM-UAKIncludes Bracket
360° UNION ADAPTER KITAllows dual 360° directional
adjustment
Each kit includesone A & one B
end cap
Add WGM-A5 or order WGM-2-BRKTfor insulated connections
Part # WGM-M-1Uses same end caps as WGM-1
End CapA
End Cap B
Allows tight90° turns for
solid wires up to.052 (1.3mm)
*See catalog orwebsite for additionaloptions & accessories
6" (152mm)
Part #WGM-WK-1-3Adjustable for
up to 3" (76 mm)thick walls
Part #WGM-3-BRKT
Side Mount Bracket
Part #WGM-PFA-STANDIncludes stand and oneadjustable extension arm
Adjustableheight from50" –86"(1.3-2.2m)
Adjustablearm lengthfrom 4" –19"(102-483mm)
Adjustableheight from50" –86"(1.3-2.2m)
Adjustablearm lengthfrom 4" –19"(102-483mm)
Wire Pilot® FeedAssist Option
Wire Wizard®Fire Resistant
Drum Covers &Dollies Available
Optionalswivel
with 90°module
Drum -or-Wood Reel Drum -or-
Wood Reel
WGM-A-10BK
Additionalarm, part #WGM-PFA-
STAND-ARM
Part #WGM-PFA-STAND
Con
duit
to w
ire fe
eder
ADJUSTABLE WALL MOUNT BRACKET
Part #WGM-FLM
Modules maybe attached to
one or bothsides
GUIDE MODULE STAND FORDRUM OR WOOD REEL APPLICATION
Wire Spool OptionWGM-PFA-STAND-4
EC-3-R (4.4mm I.D.)Fittings: A-16F-3 or A-10C-S EC-4-R (7.6mm I.D.)Fittings: A-16F-4 or A-10C-H
EC-5 (10.2mm I.D.)Fittings: A-16F-5 or A-10R
EC-6 (14mm I.D.)Fittings: A-16-F-6 or A-9
Threaded Connector
Guide Module End Cap
WGM-A5 Insulated ConnectorScrew-on Fitting(A-16F-#)
A-5 Quick DisconnectCompression(A-10##)
WIRE WIZARD® EXTRA FLEXIBLE CONDUITCONDUITS & FITTINGS
*See catalog orwebsite for additionaloptions & accessories
FC-X (6.1mm I.D.)Fitting: A-10C-X FC-XH (7.4mm I.D.)Fitting: A-10R
FC-XH-LW (10mm I.D.)Fitting: A-9
FC-X-SW* (2.3mm I.D.)Only for wire .035 & under
Threaded Connector
Guide Module End Cap
WGM-A5 Insulated ConnectorCompression(A-10##)
A-5 Quick DisconnectSwaged Fitting(Pre-cut only)
WWDPDirectPull Kit
WWDPDirectPull Kit
Standard module for wire up to 2,4mm
For larger wires look at pag 20
1/2” THREAD
female connector with 1/2” thread
fits directly into the module endcap
1,6mm
Submerged Arc Welding 1
20
WIRe guIde moduLeS FoR SaW
mecHanIcaL tuRn taBLeS
PFA motor
Submerged Arc Welding 2
PFa-unIt StandaRd Set Product Part number
PFA unit for 2,0 mm wire (installation set included) PFA20
PFA unit for 2,4 mm wire (installation set included) PFA24
PFA unit for 3,2 mm wire (installation set included) PFA32
PFA unit for 4,0 mm wire (installation set included) PFA40
Outlet guide for PFA for Large Wire Diameters A-1-BC HD
Drum mounting installation set (excl. Outlet guide) PFA-DA-HD
Filter/Regulator/Lubricator PFA-FRL
118 ml bottle PFA lubricant PFA-OIL
U-groove Feed roll 2,0mm for PFA (per piece) WW053704
U-groove Feed roll 2,4mm for PFA (per piece) WW053703
U-groove Feed roll 3,2mm for PFA (per piece) WW053707
U-groove Feed roll 4,0mm for PFA (per piece) WW05M532
A-1B-C-HD Outlet adapter
Air tool lubricant included
PFA unit is supplied as a complete set to install the PFA-unit, including all the items in this drawing, except for the drumhood.
PFA-DA-HD Drum adapter kit
drumhood
21
A-1CS PFA
PFa-FRL filer/regulator/lubricator including hose
conduItS FoR StaInLeSS SteeL & aLumInIum
conduItS FoR mILd SteeL
conduItS FoR SaW
For the large diameter wires used for SAW welding, Wire Wizard has the perfect conduits. Look at page 6 & 7 for the full range. In the tables below we show you the conduits used for SAW welding.
Part Dimensions in mm Use for Connector Order Bulk
Number inside x outside wire quantity length
FC-XH 7,5 x 15,50 mm 1,6 - 2,4 mm A-10-R Per meter 30,5 mtr
FC-XH-LW 10,0 x 19,00 mm 2,4 - 4,0 mm A-9 + A-6 Per meter 30,5 mtr
Part Dimensions in mm Use for Connector Order Bulk
Number inside x outside wire quantity length
EC-5 10,0 x 15,20 mm 1,6 - 2,4 mm A-10-R Per meter 152 mtr
EC-6 14,0 x 19,00 mm 2,4 - 4,0 mm A-9 + A-6 Per meter 152 mtr
At page 8 you can choose the right connector to fit the conduit of your choice.With these connectors you create a male bayonet connection at each side of the conduit.These bayonets will fit all female quick disconnects of the program. accept for the HD connectors.
WWtt-dP unIVeRSaL SaW connectoRThe WWTT-DP is a universal connector kit with a ceramic insert.
Body is made of Delrin for an insulated mounting.
22
Non-Stop Wire Dispensing 1
A unique process joins the end wire form a used empty drum with the start wire of the next full drum. Both butt-welding and flash removal operations take only seconds and the two wire ends may be joined during the welding cycle.
• Eliminates downtime for wire changeover
• No operator action needed - robots can continue to weld while the next full drum is being installed
• Designed for use with optional Pneumatic Feed assist or Wire guide modules
• Works with one- and two-station robotic cells (2 or 4 drums)
• Accepts any fiber drum or cardboard wire packaging design
• Easy-to-use resistantce Butt-Welder & Wire Dresser available
• Appropriate drum-handling carts available
220 Volt hand-held Buttwelder
BW-WP
Wire Parters leaves flat wire ends for easy butt-welding.
220 Volt Mini grinder to clean the weld and assure easy passage through contact tip
BW-Wd
WW-BW
WW-gB Gauge block. Made to test the buttweld after cleaning whether it is good enough to run through the contact tip.
nSW-FF Finish flag for endless wire system. Is springloaded and locked downwards when a new drum is installed. The swing pushes the flag out of its lock letting it pop up as a signal that one of the two drums is empty and a new one can be placed.
non StoP WIRe By uSIng WIRe dIRectIon SenSoRTo welding machine
or robot
short conduit few meters only
A-14BK bracket kit or PFA-unit with wall
bracket in case of large conduit length
HoW It WoRKS• Step 1 Drum is empty and wire end passes the
sensor
• Step 2 The sensor signals stops the welding
• Step 3 Disconnect conduit at “A” and place Cone at the new drum
• Step 4 Feed the new wire through the conduit
• Step 5 Weld the old wire end to the new wire end with the butt welder
• Step 6 Push the overlength into the drum and connect the conduit again at “A”
• Step 7 Start welding again
Sensor with sensor block see page 5 for article numbers
a
Framework also available as wall-mount
New!optional Barrel empty Signal Flag
23
Non-Stop Wire Dispensing 2
Wire Whip
NSWDrumHoods
Conduit
Wire Transfer Arm
Butt Welder Docking Station
Start Wire
End Wire
Start Wire
Drum 1 Drum 2
Join the end wire from drum 1 with the start wire from drum 2 using the Butt Welder.
Remove the flash in the wire joint using the Wire Sizer (or rotary tool with stone bit).
Position the wire on the path-way between the two drums.
When wire from drum 1 runs out, the transfer arm will switch over to drum 2. Simply replace emp-ty drum and repeat steps 1-3.
COMpONeNTs & BAsiC seTup
DruMseTup
1 2
3 4
Single Torch Unit(with round drums)
2-Torch Unit(with round drums)
wire pilot®
Feed Assist
May be mounted ina fixed position or
with the Guide Module Swivel Kit to allow 360°
rotation
Guide Module(s)
Additional wire exit point Options
• eliminates productionloss caused by empty drums • eliminates downtime for wire changeover
24
RWc1111-30 POLYETHYLENE WOOD REEL COVER
WRScSTAGING CART
deReeLIng aRmS FoR Wood and PLaStIc ReeLS• Universal base plate designs fits all wood or plastic reels with 1-5/16” (33mm) or 5” (127 mm) center arbors
• Twin locking cams secure base plate to reel for stability
• Springloaded drag brake provides smooth accelaration and deceleration of feed arm and prevents wire from shingling off reel
• Outer tube radius and lead will not change wire cast
• Ceramic inlet guide provides long wear and prevents wire shaving
• Large coupler bearings resists both thrust and “G” loads
• Easy installation, typically requires little adjustment
• Kits (RW#) include arm, liner, brake, base plate & quick disconnect
c33 Base Plate Most universal base plate for
European market
Fc-x Liner for mild Steel
ec-4 Liner for non ferro
RW1030-c33WIRE ARM GUIDE UNIT
For mild steel wire up to 1,6mm
with universal base plate
RW1028-c33 WIRE ARM GUIDE UNIT
For mild steel wire up to 1,6mm
with universal base plate
RW1030-c33 WIRE ARM GUIDE UNIT
For non ferro wire up to 1,6mm
with universal base plate
PFA-AS
into PFA
onto guide arm
adjuStaBLe Stand FoR PFa Wood ReeL acceSSoRIeS
PFA-AS-I
Wood reel dispensing equipment
BLue magIc™ concentRate
BLue magIc antI-SPatteR & nozzLe cLeaneR
Anti-Spatter & Accessoires
A cost effective, environmentally safe product, this new generation of anti-spatter provides superb performance even in high temperature applications. Biodegrada-ble formula contains no harmful chemicals and is noncombustible. And, because it contains one of the lowest water contents available, you get protection, not
water.
• Surfactants provides excellent wetting & lubricity in torches
• Protects against spatter build-up and char residue
• Keeps clean-ups to a minimum
• Contains no silicone-easuly painted over
• Low pH level inhibits multi-metal corrosion
• Will not evaporate keeping lines and nozzles clog-free
• Containes biocide, providing longer shelf life in warm climates
To avoid high freight costs we can also sup-ply the Blue Magic™ in a concentrate.
This concentrate is sold in 19 liter jerrycans and can be mixed with de-onized water to a total of 200 liter of Blue Magic ant-spatter.
Blue magic™ concentrateeaS1000-cc
Blue magic™ Item PaRt no.
1 Liter Bottle EAS1000-C32
3,8 Liter Bottle EAS1000-C1
19 Liter Jerrycan EAS1000-C5
200 Liter Jerrycan EAS1000-C
eaS1000-ead
Universal air chuck
BLue magIc™ ReFILLaBLe SPRay can 500 mL
The Blue Magic™ Aluminium Spray Can is a refillable and recharcheable sprayer that is designed to apply the Blue Magic™ Ant-Spatter solution. This heavy duty Aluminium spray can is easy to refill with Anti-Spatter by removing the top and easy to recharge (pressurize) by shop air with the air valve at the side.
• Saves waste - no more cans to throw away
• Can be pressurerized up to 13,50 BAR
• Universal air chuck (same as car tyre)
• With each can included are 8 extra nozzles with 4 different spray
patterns and an extra air valve
Blue magic™ nozzle dip gel Item PaRt no.
500 ML (1/2 liter) EAS1000-G16
BLue magIc™ geL FoR nozzLe dIPPIngBlue Magic™ Nozzle Dip Gel for semi-automatic welding prevents spatter and cools the nozzle temperature, increasing nozzle and contact tip life. This exclusive Blue magic™ gel formula creates a protective anti-spatter coating that will not clog orifices or threads. Simply dip the nozzle into gel and repeat as necessary.
• Long lasting formula extends nozzle and contact tip life
• Enviromentally safe, contains no silicone
• Odorless, non-toxic & non-flammable
25
Conduit and cable protection
Constructed from Kevlar, these sleeves are extremely durable and protect all cables or hoses inside against mechanical wear or shaving. Besides these cable sleeves have a spatter-resistant aluminized or silicon coating.
Protects and secures:• Wire conduit• Torch cables• Cable assemblies• Control cables• Cooling lines• Gas lines• Hydraulic hoses
Heavy duty zipper
Cable or conduit
Nylon straps with velcro
Heavy duty velcro closure
Male and female sleeve-end for
chainlink
Nylon straps with velcro
Heavy duty zipper
uSe and PoSSIBILItIeS
aVaILaBLe SIzeS and modeLS
The Aluminized coating sleeves are a perfect protection for your cable assem-bly at the torch side. It protects the expensive cable assembly of shaving and wear caused by the heat and spatters of the welding. These sleeves are for more durable then the ones made of leather. The silicon coated sleeves give protection against agressive liquids.
Step 1 Choose the right sleeve from the table
Step 2 Tighten the nylon straps around the cables
Step 3 Close the heavy duty zipper
Step 4 Chain-link the sleeves if needed
Sleeve-ends are made male/female with velcro and can be chainlinked together to get the needed length.
chainlinked sleeves
aluminized sleeve used as pro-tection for torchcable assembly against welding spatters
Aluminized sleeve used as protection against welding shaving
26
Article
Aluminized
Article
Silicon Diameter Length
KCS-2-12-A KCS-2-12-S 50 mm 30 cm
KCS-2-24-A KCS-2-24-S 50 mm 60 cm
KCS-2-36-A KCS-2-36-S 50 mm 90 cm
KCS-2-48-A KCS-2-48-S 50 mm 120 cm
KCS-3-12-A KCS-3-12-S 75 mm 30 cm
KCS-3-24-A KCS-3-24-S 75 mm 60 cm
KCS-3-36-A KCS-3-36-S 75 mm 90 cm
KCS-3-48-A KCS-3-48-S 75 mm 120 cm
KCS-4-12-A KCS-4-12-S 100 mm 30 cm
KCS-4-24-A KCS-4-24-S 100 mm 60 cm
KCS-4-36-A KCS-4-36-S 100 mm 90 cm
KCS-4-48-A KCS-4-48-S 100 mm 120 cm
Conduit and cable protection Spool and Drum accesoires
27
non-FLammaBLe dRum coVeRS
Stand FoR PFa-mountIng
To make it possible to mount either your PFA-unit or Wire Guide Modules without any support from the weldcell wall, Wire Wizard offers you a universal stand. The stand is delivered with one arm and can be extended with more arms or a
Shape Size articleRound 53 cm DC-21R
Round 60 cm DC-24R
Square 54 cm DC-21S
Square 62 cm DC-24S
Octagon 53 cm DC-21O
Octagon 60 cm DC-24O
PFa-FS Support to mountthe FRL-unit directly to the PFA
description article Universal Stand : WW-uSAdditional Arm : WW-uSaSpool holder : WW-uSSH
In case of the drum standing inside the weld cell the cardboard of the drum might get on fire caused by the heat of the welding. In case of a closed weld cell this fire might be noticed much too late causing much damage and dangerous situations.
With these non-flammable drum covers Wire Wizard offers you an effective solution to eliminate this danger.
A simple solution to locate the regulator unit of the PFA. Designed for drums standing at a track or in the middle of the shopfloor.
spoolholder. The stand is adjustable in height and small to pack and send. With this stand the PFA or modules can be located freely above the drum. This makes changing drums more easy.
28
Handling equipment 1
This dolly can be used with all kind of drums on skids or pallets measuring 69 cm square or smaller. Four solid Textite roller bearing wheels make transporting a drum simple. Can be assembled in a lip up or lip down configuration depending on customer needs. Larger sizes can be made on demand.
SpecificationsDeck Ht: 11,5 cm Height: 12,7cm Length: 70 cm Width: 70 cm Capacity: 453 kg Weight: 17 kg
FdL DRUM LIFTER WITH FdL-Fa
FdL DRUM LIFTER
dRum LIFteR, modeL FdL
• Spring loaded clamp holds drum firmly in place• For fiber or steel drums• Accepts diameters from 47 cm to 66 cm
SpecificationsWeight: 11,4 kg Capacity: 453 kg
NoTE: Drum rim must be within 25 mm of the top of the drum.Content weight must not exceed the drum manufacturers’ packing limit. Drums must be closed with lids properly sealed.
FoRK LIFt adaPteR, modeL FdL-Fa
• Adjustable T-handle keeps adapter from sliding off fork• Safety Style clasp secures adapter to drum lifter
• Weight: 3,5 kg Capacity: 500 kg
adjuStaBLe dRum LIFteR, modeL FdL-HS
• Model DL-HS accepts 51 to 66 cm drums incl. Accu pack and Marathon Pack
• Can be used with straps or handles• CE certified• Weight: 10 kg Capacity: 500 kg
ISo dRum LIFteR, modeL FdL-HS and 21
• Allows easy attachment to chimeless ISO drums• Can be used with straps or handles
• Model FDL-21, non-adjustable for 51/52 cm drums
• Model FDL-24, non-adjustable for 58/61 cm drums
• CE certified• Weight: 8 kg Capacity: 500 kg
PaLLet SKId doLLy, modeL WWSd
FdL-Fa
FdL-21
WWSdPALLET (SKID) DOLLY
FdL-HS
+ -marking
FdL-24
HeaVy duty dRum doLLy, modeLS Fdd-21/24/26• Ø Model FDD-21 for 50-52 cm drums
• Ø Model FDD-24 for 61 cm drums
• Ø Model FDD-26 for 66 cm drums
• Wide stance with four swivel casters for ease of mobility
• 7,5 cm non-conductive Textite wheels and roller bearings
Specifications
Deck Ht: 12 cm Capacity: 500 kg Weight: 10,4kg
Fdd
HeaVy duty dRum doLLy, modeL mdd-FdProduct Features
• Reversable design for large and small wire packages• Accomodates round, square & ocotogon wire drums up to 63 cm Use FDD-26 for larger drums
• Textile wheels and rolle bearings for ease of rollability
Specifications
Weight: 10,4 kg Deck Ht: 10,8 cm Capacity: 500 kg
29
Handling equipment 2
PaRt no. deScRIPtIon
RCH-2 Conduit Balancer - 1–2 kg - 1.6 mtr
RCH-4 Conduit Balancer - 2–4 kg - 2.0 mtr
RCH-8 Conduit Balancer - 6–8 kg - 2.0 mtr
CHH-10 25 cm Conduit Hanger w/two Retaining Straps
CHH-16 40 cm Conduit Hanger w/four Retaining Straps
CHH-22 56 cm Conduit Hanger w/four Retaining Straps
CONDuiT BAlANCer3 SIzES AVAILABLE • Balancer provides easy method
of hanging conduit & cables• Conduit Hanger prevents excess droopage• Prevents conduit and cables
from hanging in areas where they could get damaged
CONDuiT HANGer3 SIzES AVAILABLE
RetRactaBLe conduIt BaLanceRS & HangeRS
build up for large drums
build up for small drums
SaFety LIFteR, modeL FdL-oSLThe new Overhead Safety Lifter is designed to safety lift drums and environmental packages of wire overhead by attaching to Wire Wizard® drum and skid dollies. Each lifter includes the lifting device, heavy duty chains and adapter kit for drum
and skid dollies. Fork lift adapter sold separately.
Product Features
• Safety lifts drums or environmental packs overhead• Ideal for overhead welding applications where drums are above the cell• Compatible with the following Wire Wizard® drum and skid dollies: FDD-21 - FDD-24 - FDD-26• Capacity 680 kg• Required for lifting drums over 10” (254mm) off the floor
manuaL gaS FLoW gauge, modeL eL-gFm Measures the actual flow of shielding gas from the MIG/TIG torch, allowing adjust-ments to be made at the cylinder gauge if necessary. An economical solution for improving overall welding performance. Also easy to use at robots with the torch in downwards position.
Benefits and cost Savings
• Simple but functional design• Measures gas flow consumption (l/min) at the nozzle• Flexible hose for easier operator readings
PRecISIon gaS FLoW SenSoR, modeL eL-gmP
This hand-held digital sensor allows the operator to verify shielding gas flow rate
at the weld tip with outstanding accuracy and response.
Product Features• With totalizing function• Includes hose and filter assembly that fits over all nozzles• Pre-calibrated for argon, C25, CO2 or any mixed inert shield gas
gaS FLoW SWItcH, modeL eL-RVmu Compact design provides reliable and accurate detection of excessive or insufficient flow rate at the weld point. Calibrated scale offers visual flow rate indication for quick and easy switch adjustment. Ideal for protecting against gas flow failure.
Product Features• Can be used as normally open or normally closed• Flow range 5,5 -20 ltr/min• Switch capacity 250 V/1A/100 VA• 1/4 gas thread connection
eL-gmP
Hose not in pro-portion to gas flow sensor
Support equipment 1 (Gas)
eL-gFm
eL-RVmu GAS FLOW SWITCH
30
IneRt gaS SaVeRS• Reduces gas consumption
• Restricts gas surge upon arc starts, screen also prevents blockage
• Can be installed on the inlet or outlet side of the gas solenoid*
pArT NO. JeT 2,0 BAr 2,4 BAr 2,8 BAr 3,2 BAr 3,6 BAr 4,0 BAr
GFJ-2* 2 14,0 Ltr/Min 15,5 Ltr/Min 17,0 Ltr/Min 18,5 Ltr/Min 20,0 Ltr/Min 21,5 Ltr/Min
GFJ-3* 3 23,5 Ltr/Min 26,0 Ltr/Min 28,5 Ltr/Min 31,0 Ltr/Min 33,5 Ltr/Min 36,0 Ltr/Min Jet 2 for Mig and Tig welding /Jet 3 for heavy Mig welding
gaS SaVeR FLoW jetS
pArT NO. THreADs JeT lOCATiON
GFJ- 2D or 3D 1/4” Male NPT x 1/4” Female NPT Male End GF- F2 or F3 1/4” Male BSP-GAS x 1/4”-19 Female BSP-GAS Female End
gaS SaVeRS - IncLude ScReenS & jetS 2 or 3
GasFlow
Gas Saver with BSPP Threads (Fronius® style) GFJ-F2GFJ-F3
JETGasFlow
Gas Saver for Inlet Side of Solenoid
GFJ-2DGFJ-3D
JET
tHe BaLLoon teStCompare gas consumption after 5 seconds
of arc-on time right side = Gas saver
WP1000
(Drill not included)
Wire feed sensor, Model HHss
This hand-held battery operated tachometer is capable to measure the exact wire speed in meters per minute or meters per hour. This makes it possible to use the HHSS to calibrate your wire feeder. The HHSS also has a function to totalize the amount of wire in meters or centimeters. This function can be very helpful in order to measure the amount of welding wire used during a certain period. For example to measure the amount of wire used to weld a product. The HHSS can be placed between any male and female Wire Wizard quick disconnect. To place or remove the HHSS the wire don’t need to be cut.
Additional features• Plugs into existing wire system and conduits• Handles wire diameters from 0,8 up to 3,2 mm• Rugged aluminum construction with Delrin wire guide head• Displays wire speed with automatic floating decimal point• Also available without connector base fort hand held measuremnets at the torch.
Order articel HHSS-12 for this option
Wire drAW gAuge, Model WWPT
The electronic WWPT is designed to accurately measure the draw weight of all diameters of weld wire pulling through the conduit. This allows the operator to determine if the conduit needs to be changed by the amount of strain the wire is creating on the feed motor. Hand-held, battery powered (9-volt).
Additional features• Capable of averaging 10 pulls of wire, storing the largest draw• Measures in English or metric at the touch of a button• Easy to read 5-digit LCD display• Ergonomic plastic housing
WWPT WIRE DRAW GAUGE
HHss installed at the wire source
HHss-12 obtaining measurement at the torch end
Wire PiloT, Model WP1000
• Designed to feed weld wire from the source to the feeder• Engage/disengage wire in seconds• Accommodates 0,8 to 3,2 mm wire diameters• Changeable drive rolls
• An 800RPM or less, 10 mmvariable speed drill is recommended.
Specify wire diameters for all units when ordering
31
Support equipment 2
Open wire track